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ORNL is managed by UT-Battelle for the US Department of Energy Benchmarking EV and HEV Technologies Tim Burress Email: [email protected] Phone: 865-946-1216 This presentation does not contain any proprietary, confidential, or otherwise restricted information U.S. DOE Vehicle Technologies Office 2015 Annual Merit Review and Peer Evaluation Meeting Oak Ridge National Laboratory June 9, 2015 Project ID: EDT006

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Page 1: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

ORNL is managed by UT-Battelle for the US Department of Energy

Benchmarking EV and HEV Technologies

Tim Burress Email: [email protected]

Phone: 865-946-1216

This presentation does not contain any proprietary, confidential, or otherwise restricted information

U.S. DOE Vehicle Technologies Office 2015 Annual Merit Review and Peer Evaluation Meeting

Oak Ridge National Laboratory

June 9, 2015 Project ID: EDT006

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Overview

• Start – FY04 • End – Ongoing

• Total project funding – DOE share – 100%

• Funding received in FY14: $ 500K • Funding for FY15: $ 540K

Timeline

Budget

Barriers

Partners

• Integrating custom ORNL inverter-motor-controller with OEM components.

– Optimizing controls for non-linear motors throughout operation range.

• Intercepting, decoding, and overtaking OEM controller area network (CAN) signals.

• Adapting non-standard motor shaft and assembly to dynamometer and test fixture.

• This project helps with program planning and the establishment and verification of all DOE 2020 targets.

• John Deere • ANL • NREL

• ORNL Team members – Lixin Tang – Curt Ayers – Randy Wiles – Steven Campbell – Zhenxian Liang – Andy Wereszczak

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Project Objective and Relevance • Overall Objective: The core function of this project is to confirm power electronics

and electric motor technology status and identify barriers and gaps to prioritize/identify R&D opportunities – Assess design, packaging, and fabrication innovations during teardown of sub-systems

• Identify manufacturer techniques employed to improve specific power and/or power density • Perform compositional analysis of key components

– Facilitates trade-off comparisons (e.g. magnet strength vs coercivity) and general cost analysis

– Examine performance and operational characteristics during comprehensive test-cell evaluations • Establish realistic peak power rating (18 seconds) • Identify detailed information regarding time-dependent and condition-dependent operation

– Compile information from evaluations and assessments • Identify new areas of interest • Evaluate advantages and disadvantages of design evolutions • Compare results with other EV/HEV technologies and DOE targets

• Objectives (March 2014 through March 2015): – Complete 2014 Honda Accord HEV teardown assessments. – Conduct 2014 Honda Accord HEV dynamometer testing. – Initiate teardown of BMW i3 inverter assembly and electric motor.

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Milestones

Date Milestones and Go/No-Go Decisions Status

December 2014 Go/No-Go decision:

Identify and procure EV/HEV components. Go.

March 2015 Milestone:

Determine core functionality and general design approach of HEV/EV subsystems.

Complete.

June 2015 Milestone:

Perform initial testing on HEV/EV subsystems. On Track.

August 2015

Milestone:

Complete benchmarking tests of selected subsystem and assess design characteristics and operation with respect to 2020 DOE targets.

On Track.

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Problem to be Addressed • Without detailed knowledge of state-of-the-art technologies and their

progression, vital feedback is lacking in many areas, including: – Design and functional assessments

• Magnet and capacitor characteristics • Power control unit and electric motor design and packaging • Converter (e.g. boost, DC-DC, charger, etc.) design and packaging • Mass, volume, and power capabilities of various subsystems • Material quantities (e.g. copper mass, NdFeB mass and composition, etc) • Power density and specific power

– Operational characteristics • Efficiency maps for motor, inverter, converter, and charger • Impact of temperature limits, speed, etc. upon capabilities • Continuous duration

– Time-dependent and condition-dependent information especially important as technologies progress to long duration operation, such as electric vehicles EVs

– 55 kW for 2 seconds, 2 minutes, or 2 hours?

Benchmarking Defines State-of-the-Art

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Approach/Strategy

• Provide status of select EV and HEV technologies through assessment of design, packaging, fabrication, and performance during comprehensive testing – Compare results with other EV and HEV technologies – Confirm or provide feedback on VTO targets – Identify new areas of interest – Evaluate advantages and disadvantages of design changes, i.e.,

complexity of 3rd generation Prius PCU cooling system

• Foster collaborations with U.S. DRIVE Electrical and Electronics Tech Team (EETT) and Vehicle Systems Analysis Tech Team (VSATT)

• Publish test results and conclusions for open discussion

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2014

Oct

Nov

Dec

2015

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Go No/Go

Decision Point

FY15 Tasks to Achieve Key Deliverable

Identify and Procure Vehicle Subsystems

Conduct EDT Design Assessments

Prepare for EDT Tests

Go No/Go Decision Point: Determine if EDT components of interest are available. Key Deliverable: Annual report with findings from benchmarking assessments.

Perform EDT Benchmarking Tests

Prepare Annual Report

Key Deliverable

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Accomplishments – Previous FYs

• Compared progressing technologies - 2004 Prius, 2006 Accord, 2007 Camry, 2008 LS 600h, 2010 Prius, 2011 Sonata, 2012 Sonata generator, 2012 LEAF, 2013 LEAF charger, 2013 Camry PCU, and 2014 Accord.

2020 DOE Targets

2012 Leaf (80 kW)

2012 Sonata

HSG 23 (8.5 kW)

2011 Sonata (30 kW)

2010 Prius

(60 kW)

2008 LS600h Lexus

(110 kW)

2007 Camry

(70 kW)

2013 Camry

(105 kW)

2004 Prius

(50 kW)

Peak pow er density, kW/L 5.7 4.2 7.42 (2.7) 3.0 4.8 6.6 5.9 3.3

Peak specif ic pow er, kW/kg 1.6 1.4 1.9 (0.7) 1.1 1.6 2.5 1.7 1.1

Peak pow er density, kW/L 13.4 5.7 5.6 (2.0) 7.3 5.9 (11.1) 10.6 (17.2) 7.4 (11.7) 12.7 (19.0) 4.5 (7.4)

Peak specif ic pow er, kW/kg 14.1 4.9 5.4 (2.0) 6.9 6.9 (16.7) 7.7 (14.9) 5.0 (9.3) 11.5 (17.2) 3.8 (6.2)

Component & Parameter

Inverter

Motor

Excludes generator inverter (parenthetical values exclude boost converter mass/volume for Toyota Vehicles)

Note: All power density and specific power levels in table are not apples-to-apples. (e.g. LEAF and Sonata have continuous capability near their published rated power)

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FY15 Accomplishments – 2014 Accord • 2014 Accord is first mass produced ‘full’ hybrid by Honda

offered in U.S. • Power Converter Unit manufactured by Fuji Electric

Cooling port Cooling port

3-Phase Motor output

Mass: 17.5 kg Volume: 12.37 L

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FY15 Accomplishments – 2014 Accord Various views of 2014 Accord Power Converter Unit

Top compartment

Bottom compartment Power Module

Heatsink

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FY15 Accomplishments – 2014 Accord

Up to 700 VDC, depending on driving conditions

Converter/Inverter system similar to Toyota system

Battery PHEV (~320V) HEV(~259V)

Electrical schematic of Accord hybrid system

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FY15 Accomplishments – 2014 Accord

Bulk capacitors

Boost inductor

Thermal paste to mate inductor with

heat exchanger

Bottom Compartment of Accord Power Converter Unit

• Capacitor assembly:

• 411 uF, 370Vdc (battery input)

• 1,125 uF, 700 Vdc (boosted DC link)

• Two small 0.047uF,700 Vdc

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FY15 Accomplishments – 2014 Accord

• Same microcontroller used for motor and generator – D70F3507M1GJA2 – by Renesas, – V850 Family V850E2/Px4 – 32 bit, 512 kB Flash, 40 kB RAM, 32 kB data flash, 32 MHz, 100 pins, 22 ch x 12bit A/D,

8 channel DMA, 112 channel DTC, 11 external interrupts, 73 I/Os, 32 PWM outputs, 3-phase output function, 2 CAN channels, -40 to 125C

Bottom of control board Control board

2014 Accord Power Converter Unit – Top Compartment

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FY15 Accomplishments – 2014 Accord • Motor inverter: 2 IGBTs per switch

• Generator inverter: 1 IGBT per switch

• Boost converter: 3 IGBTs lower switch, 2 IGBTs upper switch

Motor Inverter Generator Inverter Boost Converter

2014 Accord Power Converter Unit Power Module

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FY15 Accomplishments – 2014 Accord

EMI shield

Bus bar infrastructure

Power electronics devices and integrated cooling

2014 Accord Power Converter Unit – Power Module

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FY15 Accomplishments – 2014 Accord

Motor Inverter Generator Inverter

Boost Converter

2014 Accord Power Converter Unit – Power Module

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FY15 Accomplishments – 2014 Accord

IGBT

Diode

Bus bar interfaces

12.15

11.06

15.21

12.18

Motor, generator, and boost converter IGBTs and diodes have the same dimensions: • Diode:

• 12.15mm x 11.06 mm • 134.38 mm2

• IGBT • 12.18mm x 15.21 mm • 185.26 mm2

Accord Generator Inverter Power Electronics

Page 18: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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FY15 Accomplishments – 2014 Accord

Power Module Boost inductor and

bulk capacitor housing

Accord Power Converter Unit Heat Exchanger

Close-up of fins on bottom of power module

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FY15 Accomplishments – 2014 Accord

Generator Section

Motor Section

Gear Section

Accord Transmission Sections and External Components

• Transmission mates to engine with flywheel on splined shaft

• No torque converter • Total Mass: 113.5 kg

(249.5 lbs) - Camry hybrid transmission mass is 108 kg

Page 20: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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FY15 Accomplishments – 2014 Accord • Essentially series hybrid until

engine locks in with a clutch, where the gear ratio from engine to drive-axles is: 65/19x49/61 = 2.748 – The axle rpm is about 13 times

the vehicle speed. – For engine speed of 4,000 rpm,

this gives 112 mph. – 2,000 rpm correlates to 66 mph

• Fixed gear ratio from electric motor to drive-axles – 65/19x49/20 = 8.38 – 14000 rpm 128 mph – 6536 rpm 60 mph

• Generator speed is 66/34 = 1.94 faster than engine speed

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FY15 Accomplishments – 2014 Accord

Two holes in each tube for generator end-turns

Two holes in each tube for motor end-turns

Accord Motor and Generator Cooling System

Page 22: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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• Generator and Motor stator and rotor laminations appear to be identical

– Stator OD: 29.13 cm – Rotor OD: 19.5 cm

• Motor specifications – Stack length: 6.17 cm (1.64 times generator: 3.762cm) – Rotor mass: 11.8 kg – Stator mass: 20.8 kg – Total magnet mass: 1.24 kg

FY15 Accomplishments – 2014 Accord

2010 Prius rotor lamination 2014 Accord rotor lamination

Page 23: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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FY15 Accomplishments – 2014 Accord

Accord Motor/Transmission Accord Inverter ORNL Controller

Power analyzers and other data acquisition

equipment

Accord Hybrid Inverter and Motor on Dyno

Page 24: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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FY15 Accomplishments – 2014 Accord

• Obtained three-phase voltage and phase current at the following points at ANL:

– 5 MPH, ~545 rpm

• Coast, 100 Nm, 200 Nm, 264.8 Nm 5.7 kW, 11.4 kW, 15.1 kW

– 10 MPH, ~1089 rpm,

• Coast, 100 Nm, 200 Nm, 252 Nm 11.4 kW, 22.7 kW, 28.8 KW

– 20 MPH, ~2179 rpm,

• Coast, 100 Nm, 200 Nm, 254 Nm 22.81 kW, 45.6 kW, 68.0 KW

– 30 MPH, ~3268 rpm,

• Coast, 100 Nm, 200 Nm, 254 Nm 34.2 kW, 68.5 kW, 86.9KW

– 40 MPH, ~4358 rpm,

• Coast, 100 Nm, 200 Nm, 254 Nm 45.6 kW, 91.3 kW, 115.9 KW

– 50 MPH, ~5447 rpm,

• Coast, 100 Nm, 200 Nm 57.0 kW, 114.1 kW (floored)

– 60 MPH, ~6536 rpm,

• Coast, 100 Nm, 172 Nm 68.4 kW, 117.7 kW (floored)

– 70 MPH, ~7626 rpm,

• Coast, 100 Nm, 148 Nm 79.9 kW, 118.2 kW (floored)

– 80 MPH, ~8715 rpm,

• Coast, 100 Nm, 126 Nm 91.3 kW, 115.0 kW (floored)

ORNL/ANL Collaboration (Vehicle testing)

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FY15 Accomplishments – 2014 Accord

• Motor efficiency reaches above 95% Preliminary Results: Motor Efficiencies at 300VDC

Page 26: Benchmarking EV and HEV Technologies · Benchmarking EV and HEV Technologies Tim Burress Email: burressta@ornl.gov ... – Initiate teardown of BMW i3 inverter assembly and electric

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FY15 Accomplishments – 2014 Accord

• Inverter efficiency reaches 99%

Preliminary Results: Inverter Efficiencies at 300VDC

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FY15 Accomplishments – 2014 Accord

• Combined (motor and inverter) efficiency reaches above 93% Preliminary Results: Combined Efficiencies at 300VDC

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Responses to Previous Year Reviewers’ Comments

• One reviewer noted a good report on Toyota vehicles. To another, the analysis is well done, although several questions were raised, i.e., how can the work be more widely distributed, is any effort being made to understand and document the control algorithms used, and if Argonne is doing this work, can a link or contact be provided to get access to the information? – Response: Argonne performs analysis at the vehicle level, and collaborations with

them have help established common operation conditions (e.g. speed, torque, etc) as well as maximum vehicle acceleration conditions.

– A webpage dedicated to the benchmarking project will be developed for better dissemination of information.

• One reviewer said the results are not as fast as he would like, but considering the budget and resources, he is very satisfied. A different reviewer commented that a focus on quick turnaround will result in improved value. – Response: We are working on improving the turnaround on the work. Preliminary

teardown information is available prior to the comprehensive benchmarking data, and we plan to present this information to EETT when available. Dynamometer test cell evaluations often require the design, fabrication, and assembly of complex interface hardware, and thus, there are uncontrollable delays in the process of preparation. Furthermore, the comprehensive data collected during the benchmarking efforts requires a significant amount of time for data processing, documentation, and formatting in the preparation of a final report.

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Partners/Collaborators

Logo Organization Role

John Deere Provides input and general collaboration in the area of benchmarking.

ANL

• Provides system parameters to ORNL from on-the-road tests

– Includes extreme hot/cold temperature tests • Examples:

– Coolant temperature range and common operation conditions – Battery voltage range and common operation conditions

• ORNL provides component efficiency and operational characteristics for AUTONOMIE

– Also provides to EPA, automotive manufacturers, and public

NREL ORNL provides component efficiency and operational characteristics to NREL for thermal studies.

Ames Lab Ames provides insight into magnet characterization and conducts quantitative analysis on samples from ORNL.

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Proposed Future Work

• Remainder of FY15 – Finalize comprehensive benchmarking of Accord. – Complete destructive analysis of Accord. – Complete teardown assessments of BMW i3. – Design interfaces for and instrument i3 for testing. – Initiate benchmarking of 2nd generation LEAF charger,

depending on availability.

• FY16 – Select commercially available EV/HEV systems relevant to

DOE’s VTO mission. – Perform standard benchmarking of selected system.

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Summary • Relevance: The core function of this project is to confirm

power electronics and electric motor technology status and identify barriers and gaps to prioritize/identify R&D opportunities.

• Approach: The approach is to select leading EV/HEV technologies, disassemble them for design/packaging assessments, and test them over entire operation region.

• Collaborations: Interactions are ongoing with other national laboratories, industry, and other government agencies.

• Technical Accomplishments: Tested and reported on more than eight EV/HEV systems including recent efforts on the 2014 Honda Accord inverter and motor.

• Future work: Complete Accord HEV dynamometer testing and continue benchmarking BMW i3.